Washing machine and washing method using an integrated sensing device for water level and rotating unbalance

ABSTRACT

Integrated sensing device for sensing both the water level and the rotating unbalance in a washing machine. The sensing device includes a magnetic sensor coupled to the casing of the washing machine and a magnetic body coupled to the washing tub of the washing machine. The sensed magnetic force indicates a position of the washing tub relative to the casing. While the washing water is supplied, the weight of the washing water causes the washing tub to move to a lower position and thereby the sensed magnetic force decreases. The water supply is shut off once the magnetic force decreases to a first preset value. Moreover, during a spin-drying process, if the sensed magnetic field decreases to a second predetermined value which indicates presence of rotating unbalance, the rotation is stopped and a preliminary spin-drying process is initiated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit and priority to Korean Patent Application No. 10-2014-0125757, filed on Sep. 22, 2014, with the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a washing machine and washing method using the same, and more particularly, to sensing mechanisms in a washing machine.

BACKGROUND

In general, a washing machine refers to an apparatus which eliminates foreign substances on or in laundry by agitating and rotating water together with the laundry. The washing machine typically uses a motor and performs washing, rinsing, and spin-drying processes to clean the laundry.

Washing machines may be classified into cylinder type washing machines, agitator type washing machines, and pulsator type washing machines in accordance with the structures of the washing machines. A pulsator type washing machine washes the laundry using a water flow generated by motion (e.g., rotation) of a pulsator in a washing tub.

In general, a laundry process using a washing machine includes at least a cycle of the following: a washing process, a rinsing process, and a spin-drying process.

In the washing process, the laundry is washed by moving washing water that is stimulated by the rotating pulsator. In the washing process, washing water and detergent are supplied to and contained in an outer tub of a washing tub.

At the beginning of the rinse process, the washing water with detergent in the washing tub is drained, and new water is supplied into the washing tub. Then, the inner tub of the washing tub is rotated for a certain amount of time at a relatively low speed. The aforementioned operations are repeatedly several times, followed by draining the washing water again from the washing tub.

In the spin-drying process, the inner tub of the washing tub is rotated at a high speed, thereby removing the washing water/moisture remaining in the laundry.

In the washing machine, a water level sensing device is used to sense the washing water level in the inner tub and ensure an appropriate amount of washing water is supplied to the washing tub, e.g., in accordance with the laundry load in the washing and rinse processes.

A vibration sensing device is used to sense any rotating unbalance or eccentric rotation of the inner tub during the spin-drying process. The eccentric rotation is mainly caused by the unbalanced laundry weight distribution in the inner tub.

Conventionally, a water level sensing device and a vibration sensing device are separate devices installed in a washing machine, which involves high manufacture cost and installation complexity.

SUMMARY

Therefore it would be advantageous to provide an integrated mechanism and method capable of sensing both the water level in a washing tub and the rotating unbalance of the washing tub.

Embodiments of the present disclosure provide a washing machine that can control water supply as well as prevent vibration damage to the washing machine based on detection signals generated by a single sensing device.

According to an exemplary embodiment of the present disclosure, a washing machine includes: a casing; a washing tub in the casing; a drive unit configured to rotate the washing tub; a control panel disposed on one side of an upper portion of the casing and including a circuit board; a magnetic sensor disposed on the circuit board in a direction toward an edge of the washing tub; and a magnetic body installed at the top of the washing tub and facing the magnetic sensor.

The circuit board may shut off water supply to the washing tub or stop the rotation of the washing tub in accordance with the intensity of a magnetic force measured by the magnetic sensor.

The washing tub may include a non-rotatable outer tub which stores washing water. The magnetic body is installed at the upper wall of the outer tub. An inner tub is installed inside the outer tub for accommodating clothes and can be rotated by the drive unit.

The circuit board may shut off the water supply if the detected intensity of the magnetic force is equal to or less than a first reference value, and may stop the rotation of the inner tub of the washing tub followed by performance of a preliminary spin-drying process if the detected intensity of magnetic force during a spin-drying process is equal to or less than a second reference value.

Another exemplary embodiment of the present disclosure provides a washing method which uses a magnetic body, which is provided at an edge of an upper portion of a washing tub, and a magnetic sensor, which is installed on a circuit board of a control panel so as to face the magnetic body, the washing method including: supplying washing water to the washing tub; and shutting off the water supply when an intensity of the magnetic force, which is sensed by the magnetic sensor, is at a first reference value or less.

A washing operation may be performed when the water supply is shut off.

Yet another exemplary embodiment of the present disclosure provides a washing method which uses a magnetic body, which is provided at an edge of an upper portion of a washing tub, and a magnetic sensor, which is installed on a circuit board of a control panel so as to face the magnetic body, the washing method includes: draining washing water from the washing tub; spin-drying clothes by rotating the washing tub; and stopping the rotation of the washing tub when the intensity of the magnetic force, which is sensed by the magnetic sensor, is at a second reference value or less.

The washing method may further include performing a preliminary spin-drying process when the rotation of the washing tub is stopped.

According to the exemplary embodiments of the present disclosure, the washing machine and the washing method may not only control water supply by sensing a water level of the washing tub, but also prevent damage to the washing machine by sensing unbalance.

This summary contains, by necessity, simplifications, generalizations and omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the present invention, as defined solely by the claims, will become apparent in the non-limiting detailed description set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will be better understood from a reading of the following detailed description, taken in conjunction with the accompanying drawing figures in which like reference characters designate like elements and in which:

FIG. 1 is a cross-sectional view of an exemplary washing machine including an integrated sensing device operable to both detect water level and rotating unbalance of the washing tub according to an embodiment of the present disclosure;

FIG. 2 is a flowchart illustrating an exemplary washing method using the washing machine of FIG. 1.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of embodiments of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the present invention. The drawings showing embodiments of the invention are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown exaggerated in the drawing Figures. Similarly, although the views in the drawings for the ease of description generally show similar orientations, this depiction in the Figures is arbitrary for the most part. Generally, the invention can be operated in any orientation.

Notation and Nomenclature:

It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing terms such as “processing” or “accessing” or “executing” or “storing” or “rendering” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories and other computer readable media into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or client devices. When a component appears in several embodiments, the use of the same reference numeral signifies that the component is the same component as illustrated in the original embodiment.

Washing Machine and Washing Method Using an Integrated Sensing Device for Water Level and Rotating Unbalance

Hereinafter, an exemplary washing machine 101 according to an embodiment of the present disclosure will be described with reference to FIGS. 1 and 2.

As illustrated in FIG. 1, the washing machine 101 includes a casing 500, a washing tub 200, a drive unit 800, a control panel 400, a magnetic sensor 470, and a magnetic body 700.

The washing machine 101 further includes a water supply device 560, a drainage device 580, a pulsator 300, and a suspension system 600.

The casing 500 defines an exterior housing of the washing machine 101.

The washing tub 200 is disposed inside the casing 500. Specifically, the washing tub 200 includes an inner tub 210 and an outer tub 220.

The outer tub 220 stores washing water for washing clothes (laundry).

The inner tub 210 is disposed inside the outer tub 220 and can rotate while the outer tub 220 remains stationary. The inner tub is used to accommodate clothes (or laundry). The inner tub 210 has a plurality of water holes for washing water to flow from the outer tub 220 to the inner tub 210, and vice versa.

The pulsator 300 is rotatably coupled to the bottom of the inner tub 210 of the washing tub and is operable to agitate water during the washing process.

The drive unit 800 drives the rotation of the pulsator 300 and the inner tub 210. Specifically, the drive unit 800 includes a drive motor 810, a driving shaft 830 coupled to the drive motor 810, and a clutch device 820 which can intermittently transfer rotational force to the driving shaft 830.

When the drive motor 810 rotates the pulsator 300 during a washing process, the pulsator 300 agitates the washing water along with the clothes in the washing tub 200.

When the drive motor 810 rotates the inner tub 210 during a spin-drying process, the clothes accommodated in the inner tub 210 of the washing tub 200 are spin-dried as the moisture is removed by the centrifugal force.

The water supply device 560 supplies the washing water to the outer tub 220 of the washing tub 200.

When the washing process is finished (e.g., before the spin-drying process), the drainage device 580 drains the washing water used during the washing process from the outer tub 220 to the outside of the washing machine. The drainage device 580 further includes a drain pipe coupled to the outer tub 220 of the washing tub 200, and a control valve which opens and closes the drain pipe.

The suspension system 600 has one side coupled to the outer tub 220, and the other side coupled to the casing 500. The suspension system 600 can absorb or dampen the vibration of the outer tub 220 and the inner tub 210 caused by the the rotation of the drive motor 810.

That is, the suspension system 600 supports the washing tub 200 in a suspended position and can absorb vertical vibration.

The control panel 400 is installed on one side of an upper portion of the casing 500. The control panel 400 allows a user to operate and control the washing machine 101. The control panel 400 includes a circuit board 450 including circuits for controlling several components of the washing machine 101 such as the drive motor 810, the water supply device 560, and the drainage device 580, etc.

The magnetic sensor 470 is installed on the circuit board 450. In this example, the magnetic sensor 470 is installed on the circuit board 450 and face down toward an upper edge of the outer tub 220.

The magnetic sensor 470 senses the intensity of the magnetic force generated by the magnetic body, and transmits the corresponding signals to the circuit board 450.

The magnetic body 700 is installed at an edge of the upper portion of the outer tub 220 and faces upwards towards the magnetic sensor 470. In this example, the magnetic body 700 is installed in a position at the shortest distance from the magnetic sensor 470. Accordingly, the magnetic sensor 470 senses a Gauss value of the magnetic field generated by the magnetic body 700, and thereby measures the intensity of magnetic force.

For example, the magnetic body 700 may be a permanent magnet, but the exemplary embodiments of the present disclosure are not limited thereto.

Based on the intensity of magnetic force detected by the magnetic sensor 470, the circuit board 450 may send a signal to shut off the water supply to the washing tub 200 or stop the rotation of the washing tub 200.

More specifically, when water is supplied to the washing tub 200 and the sensed intensity of magnetic force becomes equal to or less than a first reference value, the circuit board 450 may shut off the water supply. Different first reference values may be preset in a lookup table based on various laundry needs or situations, e.g., related to the type of laundry to be washed by the washing machine 101, the amount of laundry, the size and weight of the washing tub 200, and the like.

During the spin-drying process, when the sensed intensity of magnetic force becomes equal to or less than a second reference value or less, the circuit board 450 may send a signal to stop the rotation of the inner tub 210 and initiate a preliminary spin-drying process. In some embodiments, various second reference values may be preset in the lookup table based on different laundry needs and situations, e.g., related to the type of laundry, an amount of laundry, a size and weight of the washing tub, and the like.

The preliminary spin-drying process may include the operations of resupplying the washing water to the outer tub 220, and/or alternately rotating the inner tub 210 in forward and reversed (e.g., clockwise and counter-clockwise) directions.

According to the present disclosure, by using the magnetic sensing device including 470 and 700, the washing machine 101 can control the water supply based on a sensed water level in the washing tub 200, and can effectively prevent damage to the washing machine 101 based on sensed rotating unbalance.

That is, the functionalities of sensing the water level and sensing vibration are simultaneously performed using a single device including the magnetic sensor 470 and the magnetic body, advantageously resulting in simplified design configuration and improved manufacturing and installation efficiency.

Hereinafter, a washing method using the washing machine 101 according to the exemplary embodiment of the present disclosure will be described with reference to FIG. 2. The washing method is performed using the washing machine which includes the magnetic body 700 at the edge of the upper portion of the washing tub 200, and the magnetic sensor 470 on the circuit board 450. The magnetic sensor faces the magnetic body 700, as illustrated in FIG. 1.

When the washing water is supplied to the outer tub 220 for washing the laundry (S100), the weight of the washing water causes the washing tub 200 to drop from its original position (or sag) to a lower vertical position. Thus, the distance between the magnetic body 700 and the magnetic sensor 470 is increased. As a result, the intensity of magnetic force sensed by the magnetic sensor 470 decreases.

Accordingly, the water is continuously supplied to the washing tub until the sensed intensity decreases to the first reference value. In response, the water supply is shut off, and the washing operation starts, e.g., by rotating the pulsator 300 (S300).

After the washing process is finished, the washing water is drained from the outer tub 220 of the washing tub 200 to the outside of washing machine (S400), and the clothes (laundry) are spin-dried by rotating the inner tub 210 of the washing tub 200 (S500).

During the spin-drying operation, when the sensed intensity of magnetic force decreases to the second reference value or less, which indicates that the washing tub 200 is in an unbalanced state (S600), the spin-drying process is stopped in order to prevent damage to the washing machine 101.

Because an unbalanced state is mostly caused by clothes being heavily entangled during a spin-drying process, a process that disentangles the clothes can effectively attenuate or even eliminate the rotating unbalance. Here, a “preliminary spin-drying process” is used to disentangle clothes. In the preliminary spin-drying process, washing water is resupplied to the washing tub 200 (S750).

For example, the preliminary spin-drying process (S750) may include the operation of alternately rotating the inner tub 210 of the washing tub 200 in the forward and reversed directions to disentangle the clothes.

When the preliminary spin-drying process (S750) is finished, the draining operation (S400) and the spin-drying operation (S500) are performed again. So long as the sensed intensity of the magnetic force during the spin-drying operation exceeds the second reference value, the spin-drying operation is continuously performed (S800) until the washing operation ends.

With the aforementioned method, the water supply amount can be properly controlled and vibration damage to the washing machine 101 can be effectively prevented based on signals generated from a single sensing device which includes the magnetic sensor 470 and the magnetic body 700 in this example.

Although certain preferred embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the spirit and scope of the invention. It is intended that the invention shall be limited only to the extent required by the appended claims and the rules and principles of applicable law. 

What is claimed is:
 1. A washing machine comprising: a casing; a washing tub disposed inside the casing; a drive unit configured to rotate the washing tub; a control panel; and a magnetic sensing device configured to sense a water level in the washing tub and also configured to sense rotating unbalance of the washing tub.
 2. The washing machine of claim 1, wherein the magnetic sensing device comprises: a magnetic body coupled to the washing tub; and a magnetic sensor coupled to the casing and configured to generate a signal representing a distance between the magnetic body and the magnetic sensor.
 3. The washing machine of claim 1, wherein the control panel comprises control circuits and is disposed at an upper portion of the casing, and wherein the magnetic sensor is coupled to the control circuits; and wherein the magnetic body is a permanent magnet and disposed at an upper edge of the washing tub.
 4. The washing machine of claim 3 further comprising a suspension system configured to support the washing tub in a suspended state, wherein a distance between the magnetic sensor and the magnetic body increases with a weight of washing water supplied to the washing tub and laundry loaded in the washing tub.
 5. The washing machine of claim 3, wherein the control circuits are configured to shut off water supply to the washing tub or stop rotation of an inner tub of the washing tub based on a signal generated by the magnetic sensor, and wherein the signal indicates an intensity of a magnetic force generated by the magnetic body.
 6. The washing machine of claim 5, wherein the control circuits are configured to shut off water supply if the signal indicates an intensity of the magnetic force is equal to or below a first predetermined value.
 7. The washing machine of claim 6, wherein the control circuits are configured to stop rotation of the inner tub if the signal indicates an intensity of the magnetic force is equal to or below a second predetermined value.
 8. The washing machine of claim 1, wherein the washing tub comprises a stationary outer tub configured to contain washing water, and wherein the inner tub is rotatable and configured to accommodate laundry.
 9. The washing machine of claim 8, wherein, upon the rotation of the inner tub being stopped amid a spin-drying process responsive to a signal generated from the magnetic sensor, the washing machine is configured to: resupply washing water to the washing tub; alternately rotate the inner tub clockwise and counter-clockwise; and drain wash water from the washing tub and reinitiate a spin-drying process.
 10. A method of washing performed by a washing machine, the method comprising: supplying washing water to a washing tub; during said supplying, a magnetic sensor detecting a magnetic force generated by a magnetic body, wherein an intensity of the magnetic force corresponds to a position of the washing tub with reference to a casing of the washing machine; the magnetic sensor generating a signal indicating the intensity of the magnetic force; and responsive to the signal indicating the intensity of the magnetic force is equal to or below a first preset reference value, automatically shutting off the water supply.
 11. The method of claim 10, wherein the magnetic sensor is stationary and coupled to the casing of the washing machine, wherein the magnetic body is coupled to the washing tub, and wherein the position of the washing tub varies with a washing water level in the washing tub.
 12. The method of claim 11, wherein the washing tub is coupled to a suspension system that supports the washing tub in a suspended state.
 13. The method of claim 10 further comprising performing a washing operation after the water supply is shut off.
 14. A method of washing performed by a washing machine, the method comprising: draining washing water from a washing tub of the washing machine; rotating the washing tub to spin-dry laundry in the washing tub; detecting an intensity of magnetic force generated by a magnetic body coupled to the washing tub, wherein the intensity of the magnetic force corresponds to a position of the washing tub with reference to a casing of the washing tub; a magnetic sensor generating a signal based on the detecting; and automatically stopping the rotation of the washing tub when the intensity of magnetic force is equal to or less than a first preset reference value that corresponds to a rotating unbalance state of the washing tub.
 15. The method of claim 14 further comprising: performing a preliminary spin-drying process after the rotation of the washing tub is stopped, wherein the preliminary spin-drying process comprises: resupply washing water to the washing tub; alternately rotate the washing tub in forward and backward directions; and drain wash water from the washing tub and initiate a spin-drying process. 